3406e aterpillar a on lumbing - pony pack

Use this as a general plumbing guide. The photo shows a year 2000 3406E before the Pony Pack installation. Differenttruck manufacturers utilize coolant access ports differently. Understand that a good strategy may be to relocate some of

the existing plumbing to better accomodate the Pony Pack plumbing.

The four coolant plumbing tasks are explained here.

• Install the SUPPLY hose (coolant flowing from the truck engine to the Pony Pack).

• Install the RETURN hose (coolant flowing from the Pony Pack to the truck engine).

• Install the coolant fluid thermistor (New, 5/00) or 175° temperature sensor in the truck engine block.

• Install the 12 volt coolant pump in the cab heater core supply line. See instructions on reverse.

Associate the plumbing ports discussed below with the numbers in the photos. See examples on reverse.

1. Pressure port in the side of the block, 3/4 FNPT, usually available. The port is nearly always used for the Pony PackSUPPLY hose.

2. 1/2 FNPT port. Nearly always available and is the best place to install the block temperature sensor.

3-6. Oil cooler ports. 1/2 or 3/4 FNPT. Usually, two of these ports are used to supply the heater cores in the cab andsleeper. Port 6 is ideal for the Pony Pack RETURN hose. Hot coolant flows in at port 6 and immediately supplies theheater cores through ports 4 and 5. Ports 4 and 5 may also be used for the Pony Pack RETURN hose. The best solutionmay be to relocate port 6 plumbing to ports 3, 4, or 5, thus making it available for the Pony Pack RETURN hose.

7. 1/2 FNPT port on the oil cooler. May be used for the Pony Pack SUPPLY hose (coolant flowing from the truck to thePony Pack).

8. Truck water pump. These two ports on the water pump usually have the return hoses from the heater cores installed(as shown in the photo). They are not used for Pony Pack plumbing.

9. 1/2 FNPT port, difficult access. May be used for the block temperature sensor if no other ports are available.

10. There is a 1/2 FNPT port at this location. On late model engines, this port is unusable because there is no way to spinanything but a straight fitting into the block. On older engines, access is better and this location is a good candidatefor the Pony Pack RETURN hose along with a tee for the cab heater core supply.

Note: Plumbing into ports 2, 3, 4, 5, and 10 is problematic on a VOLVO, KENWORTH T2000, or FREIGHTLINERCENTURY CLASS because the engine is so far up under the firewall. Usually the air cleaner must be removedfor better access.

Note: Never move an existing temperature sensor without permission from the appropriate OEM engineering group.

PLUMBING OPTIONS ON A CATERPILLAR 3406E Pony Pack, Inc.

CAT 3406 Plumbing R02 080100

Hose from Pony Pack heat exchanger(green hose at rear of the unit) to truck oilcooler, port 6. Installed a 3/4 MNPT x 1/2FNPT adapter in the block followed by a1/4 turn 90° ball valve followed by a 1/2MNPT x 3/4 barb.

Hose from Pony Pack radiator to truckblock, port 1, 1/2 MNPT x 1/2 FNPTadapter in the block followed by a 1/2MNPT x 1/2 FNPT elbow (1/2 streetelbow) followed by a 1/2 MNPT 1/4 Turn90° ball valve followed by a 1/2 MNPT x3/4 barb.

Temperature sensor in port 2. 1/2 MNPT x3/8 FNPT adapter in the block followed bythe temperature sensor. NOTE: Do not useteflon tape or any kind of sealant on thesensor.

CAB HEAT PUMPInstall the 12 volt coolant pump in the heater core supply hose. It is an inline pump. The end barb is the inlet. The side barb is the outlet.Find the best location to cut the hose and install the pump. Consider orientation, hose bend radius, and surrounding hoses or brackets tosecure the pump with tie straps. Pad the pump and hoses as needed.

Note: Pony Pack does not recommend installing the cab heat pump in the sleeper heater core supply hose. Our experience shows thatsleeper installations become uncomfortably hot. Truck climate controls usually provide better control in the cab than the sleeper.

Rigid heater core supply lines, indicative ofFreightliner Century Class trucks. Installthe cab heat pump after the lines convert torubber hose near the frame.

To minimize heat loss, move the cab heatercore return hose (not sleeper heater core)from the radiator outlet to a suction port onthe water pump. Use a tee at the waterpump if necessary. Install a plug in theradiator outlet pipe.

Freightliner Century Class Only

Plumbing Options on a Caterpillar 3406E

CAT 3406 Plumbing R02 080100

Coolant fluid thermistor (incorporated 5/2000). Use a 1/2 MNPT x 3/8 FNPTadapter in the block followed by thethermistor. NOTE: Do not use teflon tapeor any kind of sealant on the sensor.

Cummins ISX Plumbing R03 0402101

Use this as a general plumbing guide. The overall photo shows a year 1999 Cummins Signature 600 before the Pony Packinstallation. Different truck manufacturers utilize coolant access ports differently. Understand that a good strategy may be to

relocate some of the existing plumbing to better accomodate the Pony Pack plumbing.






Note: The block and oil cooler plugs are 27mm x 2mm (thread pitch) straight thread plugs. Use a 12mm hex wrench to remove them.Pony Pack recommends installing 27mm x 2mm metric male to 3/4 FNPT bushings wherever a plug is removed. These bushings arenot common so it is a good idea to purchase several before beginning work on an ISX engine. They are available from Pony Pack.

Associate the plumbing ports discussed below with the numbers in the photos.

1-2. Pressure ports in the engine. Sometimes either port has a factory-installed sensor. Either port is suitable for the Pony PackSUPPLY hose and/or the temperature sensor.

3. This port is down low and on the end of the oil cooler. On some trucks it is inside the frame and hard to reach. If it isunused and accessible, it may be used for the SUPPLY hose.

4-6. Usually, one or two of these ports are utilized for heater core supply hoses. The unused port is the best place to plumb thePony Pack RETURN hose. If all ports are used or the plug cannot be removed, it may be necessary to use a brass street tee orsimilar arrangement to plumb two hoses into a single port. Any of these ports are also suitable for the temperature sensor iflocations 1 and 2 are not available.

Note: Plumbing into ports 4, 5 and 6, may be problematic on a VOLVO, KENWORTH T2000, or FREIGHTLINERCENTURY CLASS because the engine is so far up under the firewall. Usually the air cleaner must be removed forbetter access. It still may be difficult to loosen the straight thread plugs in this location, especially on older engines.


PLUMBING OPTIONS ON A CUMMINS ISX Pony Pack, Inc.

FITTING: The 3/4 FNPT x 27-2 MetricMale works at all plumbing locations.

Cummins ISX Plumbing R03 042101

CAB HEAT PUMPInstall the 12 volt coolant pump in the heater core supply hose. It is an inlinepump. The end barb is the inlet. The side barb is the outlet. Find the bestlocation to cut the hose and install the pump. Consider orientation, hose bendradius, and surrounding hoses or brackets to secure the pump with tie straps.Pad the pump and hoses as needed.

Note: Pony Pack does not recommend installing the cab heat pump in thesleeper heater core supply hose. Our experience shows that sleeper installa-tions become uncomfortably hot. Truck climate controls usually provide bettercontrol in the cab than the sleeper. Furthermore, on Freightliners an air overelectric valve controls sleeper coolant flow and will not work below a certainair pressure.




Port 1, Temperature sensor.3/4 FNPT x 27-2 Metric Male in the block3/4 MNPT x 1/2 FNPT adapter1/2 x 3/8 adapter

Port 2, Pony Pack SUPPLY hose.3/4 FNPT x 27-2 Metric Male in the block3/4 MNPT x 1/2 FNPT adapter1/2 MNPT quarter turn ball valve1/2 MNPT x 1/2 FNPT 90°1/2 MNPT x 3/4 MNPT Barb

Port 3, Pony Pack SUPPLY hose.3/4 FNPT x 27-2 Metric Male in the block11/2 MNPT quarter turn ball valve1/2 x 1/2 x 1/2 Street tee1/2 MNPT x 3/4 barb

Port 4, Pony Pack RETURN hose and previ-ously plumbed heater core supply hose(s).3/4 FNPT x 27-2 Metric Male in the block3/4 MNPT x 1/2 FNPT adapter1/2 x 1/2 x 1/2 street tee11/2 MNPT quarter turn ball valve1/2 MNPT x 3/4 barb (not shown)1/2 MNPT x 1/2 FNPT 45° elbow1/2 MNPT x 3/4 barb

Port 5, cab heat exchanger supply hose3/4 FNPT x 27-2 Metric Male in the block1/2 MNPT x 1/2 FNPT 45° elbow1/2 MNPT x 3/4 barb

Port 4, 5 and 6, Pony Pack RETURN hoseand previously plumbed accessories

Notice the Cab Heat Pump in the cabheater core supply hose.


Use this as a general plumbing guide. The photos show a 1997 Cummins N14 engine before the Pony Pack installation.Relative to other engine types, plumbing options on an N14 are relatively limited. Different truck manufacturers utilize

coolant access ports differently. Understand that a good strategy may be to relocate some of the existing plumbing to betteraccomodate the Pony Pack plumbing.







1. Pressure port (1/2 FNPT) located in the lower rear of the block, usually behind the exhaust, and usually available.This port is nearly always used for the Pony Pack SUPPLY hose. This location in relation to the exhaust requires addedprotection for the coolant hose. Install high temperature hose loom around the hose or a heat shield around the ex-haust.

2. Pressure port (1/2 FNPT). Trace the hose to verify that it supplies the existing cab heater core. Install the 12 voltcoolant pump in this hose.

3. Pressure port (1/2 FNPT). The the cab heater core supply is not at port 2, it may be plumbed here.

4. Pressure port (1/2 FNPT) located in the upper rear of the block, usually available. This port is nearly always used forthe Pony Pack RETURN hose.

5, 6, 7. At least one of these ports is always available. This is an ideal location for the 175° temperature sensor. Theselocations are not suitable for Pony Pack RETURN or SUPPLY hoses.

Note: Plumbing into ports 2, 3, and 4 may be problematic on a VOLVO, KENWORTH T2000, or FREIGHTLINERCENTURY CLASS, because the engine is so far up under the firewall. Usually the air cleaner must be removedfor better access.


PLUMBING OPTIONS ON A CUMMINS N14 Pony Pack, Inc.

Cummins N14 Plumbing R02 080100

Hose from Pony Pack heat exchanger(green hose at rear of the unit) to truck port4.

1/4 turn 90° ball valve in the port1/2 MNPT x 3/4 barb.

Hose from Pony Pack radiator to truckblock, port 1

1/4 turn 90° ball valve in the port1/2 MNPT x 3/4 barb.

Temperature sensor in ports 7.

1/2 MNPT x 3/8 FNPT in the port fol-lowed by the temperature sensor.

NOTE: Do not use teflon tape or any kindof sealant on the sensor.



Hose connector for Pony Pack radiator totruck block, port 1.

1/4 turn 90° ball valve in the port1/2 MNPT x 3/4 barb

The hard heater core supply lines areindicative of Freightliner Century Classtrucks.

Hose connection for Pony Pack heatexchanger (green hose at rear of the unit)to truck port 2.

1/2 FNPT x 1/2 MNPT in the port1/2 FNPT x 1/2 MNPT x 45° adapter1/4 turn 90° ball valve1/2 MNPT x 3/4 barb.

The hard heater core supply lines areindicative of Freightliner Century Classtrucks.




Plumbing Options on a Cummins N14



Use this as a general plumbing guide. The overall photo shows a year 2000 Series 60 before the Pony Pack installation.Different truck manufacturers utilize coolant access ports differently. Understand that a good strategy may be to relocate

some of the existing plumbing to better accomodate the Pony Pack plumbing.







1-2. Pressure ports in the oil cooler (3/4 FNPT) These ports are nearly always used for the cab and bunk heater core supplyhoses. Either port is ideal for the Pony Pack SUPPLY hose. One common strategy is to, a) identify the cab heater coresupply hose, b) plumb the SUPPLY hose in its place, c) tee the cab heater core supply hose in with the RETURN hose atports 4 or 5.

3. 1/2 FNPT port. This port is at the bottom of the oil cooler. Frequently it is hard to access. If it is unused and acces-sible, it may be used for the SUPPLY hose. It may also be used for the temperature sensor as a last resort.

4-5. Engine ports. 3/4 FNPT port. Really, there are three ports in this location. The center port is alway used for an enginetemperature sensor. Usually, one but not both remaining ports are utilized for a something else. The unused port is thebest place to plumb the RETURN hose. It is also the best place to plumb the cab heater core supply hose (that wasremoved from ports 1 or 2 on the oil cooler.) Use a brass street tee or similar arrangement to plumb both hoses intothe same port.

If ports 4 and 5 are both available, plumb the RETURN hose into port 4 and the cab heater core supply hose into port 5.

6-7. 3/4 FNPT port. Either of these locations are ideal for the temperature sensor.

Note: Plumbing into ports 1, 2, 3, 4, and 5, is problematic on a VOLVO, KENWORTH T2000, or FREIGHTLINERCENTURY CLASS because the engine is so far up under the firewall. Usually the air cleaner must be removed forbetter access.


PLUMBING OPTIONS ON A DETROIT DIESEL SERIES 60 Pony Pack, Inc.

DD Series 60 Plumbing R03 052202

Hose from Pony Pack heat exchanger(green hose at rear of the unit) to truckblock, port 4. Installed a 3/4 MNPT x 1/2FNPT adapter in the block followed by astreet tee with a 1/4 turn 90° ball valve inthe tee and a 1/2 MNPT x 1/2 FNPT elbow(1/2 street elbow) with a 1/2 MNPT x 3/4barb in the straight.

Hose from truck block to Pony Packradiator, port 1, 1/2 MNPT x 1/2 FNPTadapter in the block followed by a 1/2MNPT 1/4 Turn 90° ball valve followedby a 1/2 MNPT x 3/4 barb.

Temperature sensor in the truck block. 1/2MNPT x 3/8 FNPT adapter in the blockfollowed by the temperature sensor.NOTE: Do not use teflon tape or any kindof sealant on the sensor.






Plumbing Options on a Detroit Diesel Series 60

DD Series 60 R03 052202


Use this as a general plumbing guide. The photo shows a year 2000 3406E before the Pony Pack installation. Differenttruck manufacturers utilize coolant access ports differently. Understand that a good strategy may be to relocate some of the

existing plumbing to better accomodate the Pony Pack plumbing.







1,2. Suction ports on the water pump. These ports may have heater core return hoses installed.

3-5. Discharge ports on the side of the engine. They are all difficult to access.

6-8. Oil cooler ports. Discharge according to Will at Wagner Equipment, ALBQ.

9. This port is located at the top back corner of the engine. It is unuseable because you can’t spin a fitting into it.

10. Sideport on the oil cooler. suction or discharge.

Note: Plumbing into ports #, #, #, and # is problematic on a VOLVO, KENWORTH T2000, or FREIGHTLINERCENTURY CLASS because the engine is so far up under the firewall. Usually the air cleaner must be

removed for better access.


PLUMBING OPTIONS ON A CATERPILLAR C15 Pony Pack, Inc.

CAT C15 Plumbing RXX 092705

Use this as a general plumbing guide. The photos show a 1997 Cummins N14 engine before the Pony Pack installation.

Relative to other engine types, plumbing options on an N14 are relatively limited. Different truck manufacturers utilize

coolant access ports differently. Understand that a good strategy may be to relocate some of the existing plumbing to better

accomodate the Pony Pack plumbing.







1. Pressure port (1/2 FNPT) located in the lower rear of the block, usually behind the exhaust, and usually available.

This port is nearly always used for the Pony Pack SUPPLY hose. This location in relation to the exhaust requires added

protection for the coolant hose. Install high temperature hose loom around the hose or a heat shield around the ex-

haust.

2. Pressure port (1/2 FNPT). Trace the hose to verify that it supplies the existing cab heater core. Install the 12 volt

coolant pump in this hose.

3. Pressure port (1/2 FNPT). The the cab heater core supply is not at port 2, it may be plumbed here.

4. Pressure port (1/2 FNPT) located in the upper rear of the block, usually available. This port is nearly always used for

the Pony Pack RETURN hose.

5, 6, 7. At least one of these ports is always available. This is an ideal location for the 175° temperature sensor. These

locations are not suitable for Pony Pack RETURN or SUPPLY hoses.

Note: Plumbing into ports 2, 3, and 4 may be problematic on a VOLVO, KENWORTH T2000, or FREIGHTLINER

CENTURY CLASS, because the engine is so far up under the firewall. Usually the air cleaner must be removed

for better access.


PLUMBING OPTIONS ON A CUMMINS N14 Pony Pack, Inc.


Hose from Pony Pack heat exchanger

(green hose at rear of the unit) to truck port

4.

1/4 turn 90° ball valve in the port

1/2 MNPT x 3/4 barb.

Hose from Pony Pack radiator to truck

block, port 1



Temperature sensor in ports 7.

1/2 MNPT x 3/8 FNPT in the port fol-

lowed by the temperature sensor.

NOTE: Do not use teflon tape or any kind

of sealant on the sensor.

CAB HEAT PUMPInstall the 12 volt coolant pump in the heater core supply hose. It is an inline pump. The end barb is the inlet. The side barb is the outlet.

Find the best location to cut the hose and install the pump. Consider orientation, hose bend radius, and surrounding hoses or brackets to

secure the pump with tie straps. Pad the pump and hoses as needed.

Note: Pony Pack does not recommend installing the cab heat pump in the sleeper heater core supply hose. Our experience shows that

sleeper installations become uncomfortably hot. Truck climate controls usually provide better control in the cab than the sleeper.

Hose connector for Pony Pack radiator to

truck block, port 1.


1/2 MNPT x 3/4 barb

The hard heater core supply lines are

indicative of Freightliner Century Class

trucks.

Hose connection for Pony Pack heat

exchanger (green hose at rear of the unit)

to truck port 2.

1/2 FNPT x 1/2 MNPT in the port

1/2 FNPT x 1/2 MNPT x 45° adapter

1/4 turn 90° ball valve


The hard heater core supply lines are

indicative of Freightliner Century Class

trucks.

Rigid heater core supply lines, indicative of

Freightliner Century Class trucks. Install

the cab heat pump after the lines convert to

rubber hose near the frame.

To minimize heat loss, move the cab heater

core return hose (not sleeper heater core)

from the radiator outlet to a suction port on

the water pump. Use a tee at the water

pump if necessary. Install a plug in the

radiator outlet pipe.


Plumbing Options on a Cummins N14


Coolant fluid thermistor (incorporated 5/

2000). Use a 1/2 MNPT x 3/8 FNPT

adapter in the block followed by the

thermistor. NOTE: Do not use teflon tape

or any kind of sealant on the sensor.

Use this as a general plumbing guide. The photo shows a year 2000 3406E before the Pony Pack installation. Differenttruck manufacturers utilize coolant access ports differently. Understand that a good strategy may be to relocate some of

the existing plumbing to better accomodate the Pony Pack plumbing.




• Install the coolant fluid thermistor in the truck engine block.



1. Water log, 1/2 FNPT. Candidate for the Pony Pack SUPPLY OR RETURN (REX) hose.



4. Water log, 1/2 FNPT. Likely used for heater core supply hose. Note the upstream tee to supply both heater cores.



REX, where is a good spot for the temp sensor.


PLUMBING OPTIONS ON A MACK E7 Pony Pack, Inc.

Mack E7 Plumbing RX0 122001

Hose from Pony Pack heat exchanger(green hose at rear of the unit) to truck oilcooler, port 6. Installed a 3/4 MNPT x 1/2FNPT adapter in the block followed by a1/4 turn 90° ball valve followed by a 1/2MNPT x 3/4 barb.

Hose from Pony Pack radiator to truckblock, port 1, 1/2 MNPT x 1/2 FNPTadapter in the block followed by a 1/2MNPT x 1/2 FNPT elbow (1/2 streetelbow) followed by a 1/2 MNPT 1/4 Turn90° ball valve followed by a 1/2 MNPT x3/4 barb.

Temperature sensor in port 2. 1/2 MNPT x3/8 FNPT adapter in the block followed bythe temperature sensor. NOTE: Do not useteflon tape or any kind of sealant on thesensor.



Plumbing Options on a Caterpillar 3406E

Mack E7 Plumbing RX0 122001


3406e aterpillar a on lumbing - pony pack

Documents